Construction of a vacuum cleaner

ABSTRACT

A vacuum cleaner has a suction motor and fan assembly in a main airflow conduit extending between the dirty air inlet, typically in a surface cleaning head, and a filtration member.

FIELD OF THE INVENTION

[0001] This application relates to a vacuum cleaner. In one particularembodiment, this invention relates to an upright or stick vacuum cleaneror sweeper.

BACKGROUND OF THE INVENTION

[0002] Various designs for vacuum cleaners are known in the art. Vacuumcleaners require power to drive a suction fan to cause an airflow, whichentrains dirt and transports the dirt to a filtration member.Traditionally, vacuum cleaners have been developed which require asubstantial amount of power input to the suction fan to provide thedesired airflow (e.g. 10 to 13 Amp). In order to provide such amounts ofpower to a vacuum cleaner, the vacuum cleaner is provided with anelectric cord that is plugged into an AC outlet in a building.

[0003] Battery operated vacuum cleaners have been developed. Thesevacuum cleaners also require a substantial amount of battery power,which limits the run time due to the amount of power required to operatethe suction motor. The amount of batteries required to power the vacuumcleaner, have several disadvantages. These include the increased weightof the vacuum cleaner due to the batteries, the additional size of thevacuum cleaner to accommodate the batteries on board, and the limitedoperational time of the vacuum cleaner on a single battery charge if thevacuum cleaner is to have a high level of cleaning efficiency.

SUMMARY OF THE INVENTION

[0004] In accordance with the instant invention, a vacuum cleaner isprovided with a suction motor and fan assembly in a main airflow conduitextending between the dirty air inlet, typically in a surface cleaninghead, and a filtration member. For example, in an upright or stickvacuum cleaner, an airflow conduit extends from the surface cleaninghead to the filtration member in a support (e.g. an upper casing)pivotally mounted to the surface cleaning head. By positioning the motorand fan assembly in the conduit and linearly aligning the motor and fanassembly and the conduit, the number of bends in the airflow passage isreduced. Each bend in the airflow passage of a vacuum cleaner createsbackpressure and reduces the airflow rate therethrough, unless the powerdelivered to the motor and fan assembly is increased. Accordingly, in abattery-powered vacuum cleaner, a reduction in the backpressure canresult in an increase in the cleaning efficiency of the vacuum cleanerand/or an increase in the run time of the vacuum cleaner on a singlebattery charge and/or a reduction in the number of batteries.

[0005] In accordance with the instant invention, it is preferred toposition the suction motor and fan assembly exterior to the surfacecleaning head. Typically, in upright vacuum cleaners, the suction motorand fan assembly is positioned in the surface cleaning head. Thisincreases the height of the surface cleaning head and limits the extentto which the vacuum cleaner may use the surface cleaning head to cleanunder furniture. By positioning the suction motor and fan assemblyexterior to the surface cleaning head, and aligning the suction motorand fan assembly with the upper casing, then the depth of the uppercasing may be minimized while reducing the height of the surfacecleaning head, thereby enhancing the ability of the vacuum cleaner toclean under furniture.

[0006] In accordance with the instant invention, there is provided anupright surface cleaning apparatus comprising a surface cleaning headand an upper casing pivotally mounted thereto, the upper casing moveablebetween a storage position in which the upper casing extends generallyvertically upwardly from the surface cleaning head and an in useposition, the surface cleaning head having a dirty air inlet, thesurface cleaning apparatus having a clean air outlet, an air flowpassage extending between the dirty air inlet and the clean air outlet,the air flow passage including a conduit extending generally verticallyupwardly when the upper casing is in the storage position and a motorand fan assembly positioned in the conduit.

[0007] In one embodiment, the upright surface cleaning apparatus furthercomprises a filtration member positioned in the upper casing and theconduit extends between the surface cleaning head and the filtrationmember.

[0008] In another embodiment, the motor and fan assembly is positionedadjacent the surface cleaning head.

[0009] In another embodiment, the conduit has a longitudinal axis andthe motor and fan assembly has an axial flow direction and is positionedin the conduit portion such that the axial flow direction is paralleland coplanar with the longitudinal axis of the conduit.

[0010] In another embodiment, the conduit extends away from the surfacecleaning head.

[0011] In another embodiment, the motor and fan assembly is positionedexterior to the surface cleaning head.

[0012] In accordance with the instant invention, there is also provideda surface cleaning apparatus comprising a dirty air inlet, a clean airoutlet, an air flow passage extending between the dirty air inlet andthe dirty air outlet, the air flow passage in fluid flow communicationwith a motor and fan assembly, the motor and fan assembly having anaxial flow direction and the air flow passage having a portion having alongitudinal axis and a substantial linear longitudinal extent and themotor and fan assembly is positioned in the portion such that the axialflow direction is parallel and coplanar with the longitudinal axis ofthe portion.

[0013] In one embodiment, the surface cleaning apparatus furthercomprises a surface cleaning head and a filtration member and theportion extends from the surface cleaning head to the filtration member.

[0014] In another embodiment, the surface cleaning apparatus is anupright or stick vacuum cleaner.

[0015] In another embodiment, the portion comprises a generallyvertically extending airflow duct when the surface cleaning apparatus isin a storage position and the motor and fan assembly is provided in thegenerally vertically extending airflow duct.

[0016] In another embodiment, the portion comprises two generallyvertically extending airflow ducts and a motor and fan assembly isprovided in one of the generally vertically extending airflow ducts.

[0017] In another embodiment, the motor and fan assembly and the portioneach have a linear extent and the linear extent of the portion is atleast about three times the linear extent of the motor and fan assembly.

[0018] In another embodiment, the motor and fan assembly and the portioneach have a linear extent and the linear extent of the portion is atleast about five times the linear extent of the motor and fan assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] These and other advantages of the instant application may be moreclearly and fully understood in accordance with the followingdescription of the preferred embodiments of this invention asillustrated in the following drawings in which:

[0020]FIG. 1 is a schematic drawing of a vacuum cleaner according to afirst embodiment of this invention;

[0021]FIG. 1A is a perspective view of the vacuum cleaner in FIG. 1 inthe storage position;

[0022]FIG. 2 is an alternate view of the vacuum cleaner of FIG. 1 withthe dirt collection bin removed;

[0023]FIG. 3 is a schematic drawing of a vacuum cleaner of FIG. 1wherein the auxiliary above floor cleaning hose has been removed for usein an above the floor cleaning mode;

[0024]FIG. 4 is a schematic drawing of a rear view of the vacuum cleanerof FIG. 1;

[0025]FIG. 5 is a schematic top plan view of the cleaner head of thevacuum cleaner of FIG. 1;

[0026]FIG. 6 is a cross-section along the line 6-6 in FIG. 5 showing aconfiguration for the air flow pass in the vacuum cleaner head;

[0027]FIG. 7 is a cross-section along the line 6-6 of FIG. 5 showing analternate configuration for the air flow pass in the vacuum cleanerhead; and,

[0028]FIG. 8 is a top plan view of an alternate construction of a vacuumcleaner head shown in FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

[0029] As shown in the Figures attached hereto, an upright vacuumcleaner 60 has a floor cleaning head 3 and an upper assembly 62pivotally mounted thereto. It is to be appreciated that the instantinvention may be used with any vacuum cleaner including an uprightvacuum cleaner, a stick vacuum cleaner, a canister vacuum cleaner (withthe suction motor and fan assembly positioned in the wand extending fromthe surface cleaning head to the canister unit), a backpack vacuumcleaner (with the suction motor and fan assembly positioned in the wandextending from the surface cleaning head to the backpack unit) or thelike. Preferably, the vacuum cleaner is battery-operated.

[0030] As shown in FIG. 1, an upright vacuum cleaner 60 may comprise avacuum cleaner head 3 and an upper assembly 62. The vacuum cleaner has afiltration member 11 that is provided in upper assembly 62. In addition,the vacuum cleaner preferably has a rotary brush 1 that is provided incleaning head 3. In order to provide a low profile for vacuum cleanerhead 3, motor and fan assembly 15 is preferably provided as part ofupper assembly 62.

[0031] The vacuum cleaner may be provided with an on/off switch, whichmay be provided at any location of the vacuum cleaner. For example, asshown in FIG. 1, on/off toggle switch 43 may be provided on upperassembly 62.

[0032] As shown in the Figures, the vacuum cleaner may be constructed asa closed loop circulation vacuum cleaner. In particular, air containingentrained dirt is passed through filtration member 11 to produce acleaned air stream. Typically, the cleaned air stream in a vacuumcleaner is released to the room. In accordance with the design of FIG.1, the cleaned air stream is recycled through the vacuum cleaner toproduce air jets adjacent rotary brush 1 to aid in entraining dirt. Ifthe vacuum cleaner is battery operated, then in order to assist inbattery cooling, some or all of the filtered air may be directed at thebatteries to provide forced cooling in addition to or in place ofseparate cooling fans 26, 27. It will be appreciated that even if thefiltered air is not used to create air jets, that some or all of thefiltered air may be used to cool the batteries.

[0033] Referring to FIGS. 1, 6 and 7, air enters the cleaning head viainlet 64 provided in bottom surface 66 of vacuum cleaner head 3. Dirtfrom the surface being cleaned is entrained with the assistance ofoptional rotary brush 1. Suction fan and motor assembly 15 produces anair stream denoted by reference number 4 in FIG. 1, which enters duct 2.The dirty air stream passes through inlet duct 2, through up-flow duct8, through inlet port 10 and into filtration member 11. The filtered airexists filtration member 11 via outlet port 12 through down flow duct14, through motor and fan assembly 15 and into duct 17 to produce an airstream for recycling (see FIG. 1). These members define the airrecirculation loop. It will be appreciated that other configurations ofthe airflow passage through a vacuum cleaner may be provided to producean air stream for recycle. Some or all of the filtered air may be usedto cool optional batteries 5, 6 by being directed to flow over thebatteries.

[0034] Referring to FIGS. 6 and 7, duct 17 may consist of a passagewayextending through vacuum cleaner head 3 to a position in front of inlet64. Brush air ejection duct 18 is positioned at the downstream end ofduct 17 (see in particular FIGS. 1 and 8). Preferably, duct 18distributes the air laterally across the width of vacuum cleaner head 3,preferably along the entire length of rotary brush 1, and produces astream 19 of cleaned air for recycle that is directed generally parallelto the floor. The jets are angled to direct the air downwardly towardsthe floor and rearwardly towards brush 1. Preferably, the air isinjected downwardly at an angle A to the horizontal of between about 0and 15° (see FIG. 7). It will be appreciated by those skilled in the artthat duct 17 may be provided at any desired location in cleaner head 3.For example, as shown in FIG. 6, duct 17 is provided adjacent uppersurface 68 of cleaner head 3. In the embodiment of FIG. 7, duct 17 isprovided approximate bottom surface 66 of cleaner head 3.

[0035] The optional air jets produce an air stream, which travelsgenerally parallel to the floor. An advantage to this approach is thatthe air is generally directed rearwardly towards the inlet of duct 2 sothat a substantial portion, and preferably essentially all, of the airexiting ejection duct 18 enters air duct 2 and is therefore recycled.Accordingly, a substantial portion of air stream 4 entering duct 2 maycomprise recycled air. By reducing the amount of air that is exhaustedfrom vacuum cleaner 60, the amount of particulate matter, which isreleased into the room in which the vacuum cleaner is operated, is alsoreduced. A further advantage is that the kinetic energy in the exhaustair is used to entrain dirt into air stream 4. As vacuum cleaner 60 maybe battery powered, then by using the kinetic energy of air stream 19,the number of batteries required to provide a desired operating time forvacuum cleaner 60 on a single cycle of the batteries may be reduced or,if the same number of batteries are used, then air flow rate may beincreased without reducing the operating time of a single cycle of thebatteries.

[0036] It will be appreciated that if the vacuum cleaner is an uprightor a stick vacuum cleaner, that cleaning head 3 and upper assembly 62may be of any design and need not recycle air.

[0037] As shown in the preferred embodiment of the figures, the vacuumcleaner is provided with up flow duct 8 and down flow duct 14 that maybe connected to vacuum cleaner head 3 by any means known in the art.Preferably, hollow tubular members, which are in airflow communicationwith ducts 2 and 17, may be pivotally mounted to vacuum cleaner head 3.Accordingly, ducts 8 and 14 may seat on these hollow tubular members soas to complete the airflow path. For example, up flow duct 8 and downflow duct 14 may be rigid structural members that are themselvespivotally mounted to vacuum cleaner head 3. Alternately, up flow duct 8and down flow duct 14 may be mounted on a pivotal airflow tube similarto pivotal airflow valves known in the vacuum cleaner art. Alternately,as shown in FIG. 1A, up flow duct 8 and down flow duct 14 may beconnected in airflow communication with cleaner head 3 via flexibletubes 9 and 16 respectively. In this latter case, upper assembly 62 ismechanically secured to pivotally mounted cross member 170, which doesnot form part of the airflow path. Pivotally mounted cross member 170has axle portions 172 at the opposed ends thereof which are pivotallymounted to sidewalls 174 of cleaner head 3. A similar construction maybe used if only a single generally vertically extending duct 8 isprovided.

[0038] It will be appreciated that ducts 8, 14 are preferably rigidmembers, which provide a stable support for filtration member 11.Alternately, ducts 8, 14 may be flexible and rigid reinforcing membersmay be provided to provide a support or platform for filtration member11 may be supported.

[0039] It will be appreciated that if the vacuum cleaner is an uprightor stick vacuum cleaner, it may have only one airflow duct 8, 14 It willalso be appreciated that ducts 8, 14 need not be spaced apart. Forexample, they may be positioned side by side. In addition, the samemounting means may be used if there is a single duct 8, 14. For example,if none of the filtered air is recycled, then there is no need toprovide a duct 14. In such a case, filtration member 11 may be mountedonly on duct 8. Alternately, a support member similar to duct 14, butthrough which there is no air flow, may be provided so as to provide twosupports for filtration member 11. Alternately, if suction motor and fanassembly 15 is cooled by the filtered air as is known in the art, thenduct 14 may be provided to deliver filtered air to a motor and fanassembly 15 mounted in cleaning head 3.

[0040] It will be appreciated by those skilled in the art thatfiltration member 11 may be any filtration member known in the art.Preferably filtration member 11 comprises at least one cycloneseparator. For example, filtration member 11 may be a cyclone bin orcanister whereby inlet port 10 functions to direct the air tangentiallyinto a cyclone bin. It will also be appreciated that filtration member11 may comprise a plurality of cyclones which may be provided in one ormore cyclonic cleaning stages. However, it will also be appreciate thata physical filter element may also be utilized if desired. In such alatter case, the filtration member may be replaceable or washable. Iffiltration member comprises a cyclone bin, then the cyclone bin ispreferably transparent.

[0041] Filtration member 11 is optionally secured to upper assembly 62by upper cover assembly 25 (see FIG. 2). Pursuant to such an optionalembodiment, upper cover assembly 25 of filtration member 11 mayincorporate inlet port 10 and outlet port 12. Upper cover assembly 25may accordingly provide the lid for filtration member 11 (e.g. iffiltration member 11 is a cyclone bin, then upper cover assembly 25 maycomprise the lid of the cyclone bin). Inlet port 10 and outlet port 12are optionally removably mounted on ducts 8, 14 thereby permittingfiltration member 11 to be removed from vacuum cleaner 60 for empting bylifting filtration member 11 and cover 25 upwardly off of ducts 8, 14.In this way, filtration member 11 may be transported while stillessentially sealed to a garbage can or refuse container for emptying. Itwill be appreciated that if the filtered air is not recycled, then thefiltered air may be directed to the ambient via outlet port 12. Further,if the vacuum cleaner only has one duct 8, 14, then an outlet port 14 incover 25 is not required. The air may exit the vacuum cleaner via anoutlet port provided in filtration member 11 itself.

[0042] Preferably, filtration member 11, once removed from the vacuumcleaner, is emptied by removing cover 25 and inverting filtration member11 so the contents empty into a garbage can or refuse container by meansof gravity. An advantage of this design is that a user need not bendover to remove filtration member 11 or to empty a cyclone bin. It willbe appreciated that, in an alternate embodiment, filtration member 11may be a porous member that is disposable or washable. Such a filtrationmember may be designed to be washed while in a rigid housing thatdefines filtration member 11 or, alternately, filtration member 11 maybe disposable. In any such case, a consumer may lift upwardly to removethe filtration member 11 and to then place a new, cleaned or emptiedfiltration member 11 on ducts 8, 14. If will be appreciated that, iffiltration member 11 is not disposable, cover 25 may be permanentlyaffixed to filtration member 11 if a door or other openable cover memberis provided to allow the filtration member to be removed for cleaning oremptying. If will also be appreciated that, if filtration member 11 isdisposable, cover 25 may be permanently affixed to filtration member 11and no other openable cover member need be provided.

[0043] Upper cover 25 may be secured to upper assembly 62 by any meansknown in the art. In one preferred embodiment, cover assembly 25 issecured in position by at least one magnet and, preferably, a pluralityof magnets. For example, referring to FIG. 2, duct 8 is provided with amagnet 33. The upper face of magnet 33 may have any desired polarity(i.e. north or south). A magnet 32 is provided in housing of inlet tube10 so as to be aligned with magnet 33 when upper cover 25 is mounted onupper assembly 62. The lower or bottom face of magnet 32 has theopposite polarity of the upper or top face of magnet 33. Accordingly,when duct 8 is in airflow communication with inlet port 10, magnets 32and 33 assist in securing, or secure, cover 25 on duct 8. A similar pairof mating magnets may be provided on duct 14 and the housing of outletport 12. It will be appreciated that any other means to removably affixcover 25 to filtration member 11, which is known in the art, may beused. For example, the physical engagement of male and female membersmay be utilized (e.g. cover 25 may be screwed onto filtration member 11,a release button or catch may be used, a bayonet mount may be used).

[0044] In conventional vacuum cleaners, the cleaned air is fed past themotor prior to the air exiting the vacuum cleaner. In this way, thecleaned air is used to cool the motor such that the air that exits thevacuum cleaner is heated. If the filtered air is recycled, as optionallyexemplified herein, and also used to cool motor 15, then the air in therecirculation air stream exiting duct 17 in cleaner head 3 is heated.The air is therefore preferably cooled as it passes through the vacuumcleaner prior to again encountering motor 15. Accordingly, at least aportion of the airflow passage through the vacuum cleaner is preferablyconstructed from metal. For example, one or more of duct 2, flexiblehose 9, up flow tube 8, down flow tube 14, flexible tube 19, duct 17 andduct 18, as well the housing for motor 15, may be made from metal. Someor all of these surfaces may be provided with pin fins or other heatdissipation members. In addition, one or more fans may be provided topass cooling air over the ducts to assist in dissipating the heat.Preferably, a substantial number of the components of the air flow pathand, most preferably, all or essentially all of the components of theairflow path are made from metal. The metal provides a heat sink foradsorbing heat produced by motor 15. By constructing a substantialportion of the vacuum cleaner from metal, a large heat sink is provided.Further, the surface area available for dissipating the heat to theambient is also increased.

[0045] Optional rotary brush 1 may be driven by any means known in theart. For example, as shown in FIG. 1, rotary brush 1 is provided with abrush motor 48, which is drivingly connected to gear 49. Similarly, gear51 is drivingly connected to rotary brush 1. A fan belt 50 extendsaround gears 49 and 51 so as to drivingly connect brush motor 48 torotary brush 1. In such an embodiment, rotary brush 1 may be selectivelyengaged and disengaged by means of an on/off toggle switch 44. Thus,brush 1 may be shut off when it is not required, such as when anextension hose 21 is in use for above floor cleaning.

[0046] In an alternate embodiment (not shown), gear 49 may be driven byan air turbine. Preferably the air turbine is provided in air duct 17.An advantage of this design is that the air turbine would be driven byclean air. Generally, an air turbine comprises a turbine provided withina housing. As clean air would be used to power the turbine, the air gapbetween the outer end of the blades of the air turbine and the innerwall of the housing may be reduced, thus increasing the amount of power,which may be obtained from an air turbine. In addition, the turbinewould be powered by pressurized air (i.e. it is downstream from suctionfan and motor assembly 15) as opposed to a negative pressure (e.g. ifthe air turbine was provided upstream of suction fan and motor assembly15).

[0047] Optionally, duct 2 may include a portion, such as a trough shapedmember, for accumulating material prior to the material being fed withthe air stream to filtration member 11. For example, if an area of heavydirt concentration is encountered, the airflow may not be sufficient toentrain all of the dirt. By providing a storage area, the excessmaterial which is not entrained may be stored for entrainment in the airstream once the concentration of material being entrained in air stream4 decreases.

[0048] In accordance with the instant invention, motor and fan assembly15 is provided in one of ducts 8, 14. In the embodiment shown in FIG. 1,motor and fan assembly 15 is provided in the clean air stream, e.g. indown flow duct 14. Accordingly, the vacuum cleaner is a clean air system(i.e. the air has already been filtered prior to the air encounteringthe suction fan). It will be appreciated that, in accordance with analternate embodiment, suction fan and motor assembly 15 may be providedin up flow duct 8. In such a case, motor and fan assembly 15 is providedin the dirty air stream, e.g. in up flow duct 8. Accordingly, the vacuumcleaner is a dirty air system (i.e. the air has already been filteredprior to the air encountering the suction fan). In either case, anadvantage of such a preferred design is that the motor and fan assemblyis provided exterior to cleaning head 3. Typically, the suction motorand fan assembly is the largest element provided in a vacuum cleanerhead thus setting the necessary vertical height of a vacuum cleaner head(i.e. the distance from bottom surface 66 to upper surface 68). Byremoving suction fan and motor assembly 15 from cleaner head 3, thevertical height of cleaner head 3 may be reduced. This reduces theprofile of cleaner head 3 enabling it to pass underneath furniturehaving a lower clearance from the floor.

[0049] Preferably, suction motor and fan assembly 15 are axial aligned(i.e. the fan is mounted on an axle that extends outwardly from thesuction motor and rotates about that axle such that the air passessequentially through the suction motor and the fan). By positioningsuction fan and motor assembly 15 so that its longitudinal direction(i.e. the direction defined by the axle upon which the suction fan ismounted for rotation) is parallel to and in the same plane as the axisof ducts 8 and 14, the profile of upper assembly 62 (i.e. the width ofupper assembly 62 from the front surface thereof to the rear surfacethereof) may be reduced thus creating a low profile for upper assembly62. When it is desired to vacuum underneath furniture, upper assembly 62may be lowered so as to extend rearwardly behind cleaner head 3. In thisconfiguration, the extent to which cleaner head 3 may extend underneathfurniture is limited by the extent that upper assembly 62 extendsvertically above the surface being cleaned. By positioning suction fanand motor assembly 15 in one of ducts 8 and 14 and aligning the axle ofthe motor and fan assembly with the longitudinal axis of the duct, thevertical extent of upper assembly 62 when in this configuration isminimized thus increasing the ability of the vacuum cleaner to cleanunderneath furniture. Also, such an arrangement also reduces thebackpressure through the vacuum cleaner, by reducing the number of bendsin the airflow passage, and therefore reduces the power required toobtain the same airflow rate through the vacuum cleaner.

[0050] If the vacuum cleaner is battery-powered, then the batteries tooperate the vacuum cleaner 60 may be provided at any location. Batteries5, 6 are preferably mounted in cleaner head 3 so as to reduce handweight of the handle of the vacuum cleaner. For example, referring toFIG. 1, two battery sticks 5, 6 are provided in cleaner head 3. Thebatteries may be individually mounted in vacuum cleaner 60 or they maybe provided in one or more battery sticks as is known in the batteryart. The number of batteries will depend upon a number of factorsincluding the operational time of vacuum cleaner 60 on a single chargeand the airflow rate produced by motor 15.

[0051] The batteries may be provided with an airflow stream to cool thebatteries during charging and/or discharging. The cooling air ispreferably provided by one or more cooling fans 26, 27 that arepositioned to blow cooling air over the batteries 5 and 6. Preferably afan is provided for each battery stick. As shown in FIG. 1, the coolingfans 5, 6 are preferably positioned to blow air longitudinally along thelength of a plurality of batteries or a battery stick.

[0052] The batteries may be charged in situ. In such a case, the vacuumcleaner is provided with a power cord 45 and a battery charging controlcircuit. Any charging circuit known in the battery art may be used. Inone embodiment, the vacuum cleaner may be configured to also operate onAC power, e.g., when the batteries are discharged. Accordingly, powercord 45 may be any cord known in the vacuum cleaner art. However, ifvacuum cleaner 60 is not designed to operate on AC power (i.e. it onlyoperates on batteries 5, 6), then power cord may be relatively short(e.g. from 1 to 10 feet long, preferably from about 1 to 6 feet long andmost preferably about 3 feet long). If the vacuum cleaner includes thepower control system for charging the batteries (e.g. if may be a partof electronic control board 7), and if the vacuum cleaner operates onlyon batteries, then power cord 45 may be of a thinner gauge. In such acase, the power cord may be 16-18 gauge. Thus, a relatively lightweightcord may be used. Advantageously, this requires a smaller volume tostore the cable and a lighter spring may be used on an automatic cordrewind mechanism.

[0053] The power cord may be secured in position when it is not in useto charge the batteries by, e.g., a holder 46 provided on one of ducts8, 14. A battery life indicator 47 may be provided, such as onelectronics board 7. Battery life indicator is preferably a read out,and more preferably a digital readout, showing the operating timeremaining in the battery cycle.

[0054] Batteries 5, 6 are preferably removed prior to the disposal ofthe vacuum cleaner. Thus, an optional openable panel 34 is preferablyprovided in cleaner head 3 so as to permit access to the compartment inwhich batteries 5, 6 are placed. For example, panel 34 may be pivotallymounted to permit it to be opened or it may be removable mounted thevacuum cleaner. Preferably, as shown in FIGS. 1 and 8, cover 34 isprovided in upper surface of cleaner head 3 with the batteriespositioned immediately under cover 34. Cover 34 is preferablytransparent so as to permit the batteries to be visible to the user.This facilitates the user locating the batteries when they are to bereplaced (e.g., the batteries have been subjected to the recommendednumber of charging cycles) or removed for disposal. Cover 34 may besecured to cleaner head 3 by any means known in the art. For example,cover 34 may be secured by male and female engagement members.Alternately, a plurality of screws 35, 36, 37 and 38 may be providedaround the perimeter of cover 34 to secure cover 34 to cleaner head 3.

[0055] The vacuum cleaner may include an electronic control board 7,which regulates the power to suction fan and motor assembly 15.Alternately, or in addition, board 7 may also perform other functions.If vacuum cleaner 60 contains optional board 7, then board 7 ispreferably provided in cleaner head 3 so that it is visible to the user.To this end, board 7 may be provided under transparent openable cover 34or under a separate transparent cover (not shown).

[0056] It will be appreciated that board 7 and batteries 5, 6 may beprovided in a variety of configurations. For example, as shown in FIG.1, board 7 may be provided to the rear of batteries 5, 6. Alternately,as shown in FIG. 8, board 7 may be provided in front of batteries 5, 6.In an alternate embodiment, which is not shown, board 7 may be providedbetween batteries 5, 6.

[0057] In order to cool board 7, a fan 28 may be provided to directcooling air over board 7. Alternately, or in addition, one or both ofbattery cooling fans 26 and 27 could be utilized to provide cooling airto board 7, depending upon the position of board 7 and the direction ofthe air flow which is produced by fans 26, 27. It will be appreciatedthat if vacuum cleaner 60 is not battery-powered, a board 7 is notrequired.

[0058] Vacuum cleaner 60 may be provided with at least one LED andpreferably a plurality of LED's, which are directed so as to function asheadlights for the vacuum cleaner. Preferably, each headlight comprisesat least 2 LEDs and more preferably from 2 to 8 LEDs and most preferablyfrom 2 to 4 LEDs. Thus a vacuum cleaner may have 2 headlights each ofwhich has, for example, 2 to 4 LEDs.

[0059] The LEDs may have a light intensity of at least 500 minicandella(mcd). Preferably, the LED's are super bright LED's. Generally, superbright LEDs are considered in industry to be any LED having a lightintensity of at least about 1,000 mcd and may have a light intensity ofup to 13,000 mcd or more. Preferably super bright LEDs which are used ina vacuum cleaner as disclosed herein have a light intensity from 1,000to 10,000 mcd, more preferably from 2,000 to 8,000 mcd and mostpreferably from 2,000 to 4,000 mcd. Accordingly a headlight having 2LEDs may have a light intensity of from 4,000 to 16,000 mcd.

[0060] Preferably, the LED's are provided directly on board 7 tominimize wiring of the lights. For example, as shown in FIG. 1, LED's 41and 42 are provided as headlights. The LED's may be provided with orwithout a reflector to concentrate and direct the light produced by theLED's.

[0061] Optionally, filtration member 11 may comprise a transparent or atleast translucent portion and, preferably, all of filtration member 11is transparent or at least translucent. The use of a transparent ortranslucent filtration member, in combination with the use of optionalLEDs, permits a user to view the interior of the filtration member.Preferably, filtration member 11 is a cyclone bin, such as is known inthe art. In this preferred embodiment, vacuum cleaner 60 includes atleast one, and preferably a plurality of LED's (for example LED's 39 and40), which are angled so as to illuminate the transparent filtrationmember 11. The LED's may be angled so as to illuminate the filtrationmember 11 only when the vacuum cleaner is being used to clean a carpet(the normal carpet cleaning position wherein upper assembly 62 is angledrearwardly behind cleaner head 3), when the vacuum cleaner is in theupright or storage position (e.g. upper assembly 62 extends generallyvertically upwardly from cleaner head 3) or when in both positions. TheLED's may provide constant illumination or they may be strobed toilluminate the motion of dirt within a transparent or translucentcyclone bin. Preferably the LED's are super bright LED's. In thisembodiment, board 7 is preferably positioned so that the LED's may shineupwardly onto the cyclone bin. Accordingly, it is preferred to positionboard 7 towards the rear of cleaner head 3, (e.g. as shown in FIG. 5).To aid in construction, a transparent cover is preferably provided overthe portion of board 7 on which LEDs 39, 40 are positioned so that thelight from the LEDs is directed at filtration member 11. This ispreferably cover 34. If a transparent cover is not provided, then anopening may be provided in upper surface 68 of cleaner head 3.Alternately, the LEDs may be mounted on an exterior surface of thevacuum cleaner.

[0062] The vacuum cleaner may have an optional extendible stretch hose21 for use in above the floor cleaning. In such an embodiment, a valve20 is provided to connect flexible hose 21 in airflow communication withsuction fan and motor assembly 15. As shown in FIG. 1, valve 20 may beprovided in up flow duct 8. Valve 20 may be any valve known in the art.An advantage of providing valve 20 in duct 8 is that the construction ofvacuum cleaner head 3 is simplified. In particular, a valve structureneed not be incorporated into the pivotal connection of the upperassembly 62 to cleaner head 3 but may be provided in cleaner head 3 asis common in the industry.

[0063] In another embodiment, the optional extension wand for the abovefloor cleaning hose 21 preferably also functions as the handle for thevacuum cleaner. As shown in FIG. 2, according to this alternateembodiment, hose 21 is provided with a rigid tube 22. When mounted onthe vacuum cleaner, tube 22 functions as the handle for the vacuumcleaner. When removed from the vacuum cleaner, tube 22 functions as anextension wand so that the dirty air travels through wand 22 into hose21 and then into up flow duct 8 via valve 20. An advantage of thisconstruction is that tube 22 may be used both as the handle for thevacuum cleaner as well as an extension for hose 21.

[0064] Tube 22 may be removably mounted to upper assembly 62 by anymeans known in the art. In accordance with an alternate embodiment ofthis invention, the mount for releasable receiving tube 22 preferablyalso functions as a carry handle for the vacuum cleaner such as, forexample, mount 24 (see FIG. 4). In this embodiment, mount 24 comprises afirst portion for releasable receiving tube 22 and a second portion forsecuring the first portion to upper assembly 62. The first portion maycomprise a dovetail receiver 29 which is configured for receivingdovetail 23 which is provided on tube 22. The second portion maycomprise one or more rigid rods 52 which extend outwardly fromfiltration member 11 to provide a securing point for dove tail receiver29 and to permit a user to pick up vacuum cleaner 60 using mount 24. Itwill be appreciate that other releasable engagement means may beutilized. An advantage of this construction is that when tube 22 isdetached from the vacuum cleaner as shown in FIGS. 3 and 4, mount 24provides a user with a handle which may be used to move vacuum cleaner60. Accordingly, a rigid handle is always accessible to the user tofacilitate moving the vacuum cleaner regardless of whether tube 22 is inthe above floor cleaning position.

[0065] Referring to FIG. 2, upper assembly 62 may comprise up flow duct8, down flow duct 14 and one or more cross members to dynamicallystabilize ducts 8 and 14 and define a space frame. For example,referring to FIG. 2, cross-members 30 and 31 are provided to limit and,preferably, prevent any relative motion of duct 8 with respect to duct14. Preferably, support member 30, 31 dimensionally stabilize ducts 8and 14 in two dimensions (i.e. to prevent ducts 8 and 14 bending forwardor backwards relative to each other or to prevent side to side motion ofducts 8, 14). For example, support members 30, 31 may be ovals thuscross-stabilizing ducts 8, 14. Preferably, ducts 8, 14 and supports 30,31 are made from metal (e.g. aluminum). This provides a rigid,lightweight construction, which may weigh less than conventional plasticcover casings, which are manufactured for vacuum cleaners. It will beappreciated that if ducts 8, 14 are sufficiently stiff, then nocross-members may be required.

[0066] A supplemental filtration media 13 may be provided in down flowduct 14 (see FIGS. 1 and 2). In accordance with this embodiment, as thecleaned air exits filtration member 11, the air travels through outletport 12 and then through filtration member 13 as the air travelsdownwardly through duct 14. Filtration member 13 may be removed forcleaning or replacement whenever cover 25 is removed from upper assembly62. When cover 25 has been removed from upper assembly 62, filtrationmember 13 may merely be lifted upwardly out of duct 14 therebypermitting filter media 13 to be cleaned or replaced. An advantage ofthis design is that the interior volume of an airflow duct is utilizedto house a supplemental filtration member thereby reducing the overallprofile of vacuum cleaner 60.

[0067] It will be appreciated by a person skilled in the art that abattery-operated vacuum cleaner may use one or more of the differentembodiments disclosed herein and the different embodiment may becombined in any combination of features to provide a unique vacuumcleaner.

1. An upright surface cleaning apparatus comprising a surface cleaninghead and an upper casing pivotally mounted thereto, the upper casingmoveable between a storage position in which the upper casing extendsgenerally vertically upwardly from the surface cleaning head and an inuse position, the surface cleaning head having a dirty air inlet, thesurface cleaning apparatus having a clean air outlet, an air flowpassage extending between the dirty air inlet and the clean air outlet,the air flow passage including a conduit extending generally verticallyupwardly when the upper casing is in the storage position and a motorand fan assembly positioned in the conduit.
 2. The upright surfacecleaning apparatus as claimed in claim 1 further comprising a filtrationmember positioned in the upper casing and the conduit extends betweenthe surface cleaning head and the filtration member.
 3. The uprightsurface cleaning apparatus as claimed in claim 1 wherein the motor andfan assembly is positioned adjacent the surface cleaning head.
 4. Theupright surface cleaning apparatus as claimed in claim 1 wherein theconduit has a longitudinal axis and the motor and fan assembly has anaxial flow direction and is positioned in the conduit portion such thatthe axial flow direction is parallel and coplanar with the longitudinalaxis of the conduit.
 5. The upright surface cleaning apparatus asclaimed in claim 1 wherein the conduit extends away from the surfacecleaning head.
 6. The upright surface cleaning apparatus as claimed inclaim 1 wherein the motor and fan assembly is positioned exterior to thesurface cleaning head.
 7. A surface cleaning apparatus comprising adirty air inlet, a clean air outlet, an air flow passage extendingbetween the dirty air inlet and the dirty air outlet, the air flowpassage in fluid flow communication with a motor and fan assembly, themotor and fan assembly having an axial flow direction and the air flowpassage having a portion having a longitudinal axis and a substantiallinear longitudinal extent and the motor and fan assembly is positionedin the portion such that the axial flow direction is parallel andcoplanar with the longitudinal axis of the portion.
 8. The surfacecleaning apparatus as claimed in claim 7 further comprising a surfacecleaning head and a filtration member and the portion extends from thesurface cleaning head to the filtration member.
 9. The surface cleaningapparatus as claimed in claim 7 wherein the surface cleaning apparatusis an upright or stick vacuum cleaner.
 10. The surface cleaningapparatus as claimed in claim 9 wherein the portion comprises agenerally vertically extending airflow duct when the surface cleaningapparatus is in a storage position and the motor and fan assembly isprovided in the generally vertically extending airflow duct.
 11. Thesurface cleaning apparatus as claimed in claim 9 wherein the portioncomprises two generally vertically extending air flow ducts and a motorand fan assembly is provided in one of the generally verticallyextending airflow ducts.
 12. The surface cleaning apparatus as claimedin claim 7 wherein the motor and fan assembly and the portion each havea linear extent and the linear extent of the portion is at least aboutthree times the linear extent of the motor and fan assembly.
 13. Thesurface cleaning apparatus as claimed in claim 7 wherein the motor andfan assembly and the portion each have a linear extent and the linearextent of the portion is at least about five times the linear extent ofthe motor and fan assembly.